A wastewater treatment facility faced operational disruptions due to ongoing premature failures of a critical non-metallic sprocket, found within the chain-scraper style of sludge removal system used in the primary clarification tanks. 

The chain driven system heavily depended on the durability of a specific sprocket design, but the original plastic and bronze inner sleeve was proving inadequate. The original sprocket, comprised of a plastic body and a bronze sleeve fitted over a steel hub for power transmission, experienced failure where the bronze and plastic were joined, due to excessive flexing. The absence of original drawings presented a unique challenge for traditional replacement methods. 

In response to the challenge, Millstream Engineering adopted an innovative approach to retrofit the sprocket. Recognizing the limitations of the original design, they opted for Thordon Regular material, a high-strength elastomer alternative. This eliminates the need for the inner bronze sleeve, allowing the sprocket to run freely on the steel hub in the event of breakage of the shear pin.  The proper shear-pin function is essential to prevent damage to other components in the chain drive system in case of overloading due to a jam or breakage of other components.

Additionally, Millstream leveraged advanced technology, conducting 3D scanning and modeling using CAD software. This comprehensive approach ensures that the replacement part will seamlessly integrate into the existing system.  From the 3D model files, a new drawing of the replacement component was prepared so that the customer will always have an accurate record of what exactly was supplied and installed so that ordering future replacements will be simplified.

Millstream Engineering successfully delivered a custom-designed sprocket that not only addressed the immediate failure but also provided a long-term, efficient solution for the wastewater treatment facility. Despite the lack of original drawings, the innovative combination of Thordon Regular material, 3D scanning, and precise engineering allowed Millstream to provide a tailored and effective solution.

Millstream Engineering’s innovative retrofitting approach demonstrates their commitment to providing practical and effective solutions, even in challenging scenarios with no original drawings. The successful execution of this project has solidified Millstream as a trusted partner for the wastewater treatment facility’s ongoing maintenance and retrofitting needs.